Tag: right size packaging

Is Cheap Packaging a False Economy?

Posted on by definitionconsulting

When it comes to packaging, many manufacturers are tempted to seek out the lowest cost option. On the surface, it seems a simple way to protect margins. But scratch beneath the surface and it quickly becomes clear: cheap packaging can end up costing your business far more in the long run.

 

The Hidden Costs of Cheap Packaging

First off, simply going too cheap on cardboard boxes risks them failing the basic function of protecting your product. It often leads to over-reliance on void filler and still leaves goods exposed to transit damage. Damaged products mean costly returns and can harm your reputation with customers.

When products are poorly packed, they also take up more space, resulting in higher transport costs. More deliveries, higher emissions and wasted space all combine to erode any initial savings made by selecting a lower-priced box.

Assembly time is another hidden cost. Complicated or flimsy packaging designs can slow down your operations significantly. Labour costs creep up when employees spend longer building, securing or replacing poor-quality boxes. This extra time drains resources that could otherwise be spent more productively.

If you are considering making a change, learn how to choose the right corrugated board for your packaging to make sure you select the right solution.

 

How to Reduce Packaging Costs

Reducing packaging costs doesn’t mean automatically choosing the cheapest materials. Instead, smart manufacturers look for ways to improve efficiency. High-quality, fit-for-purpose packaging can lower damage rates, speed up assembly and make logistics more cost-effective.

One simple but effective strategy is to design packaging that is easy and quick to assemble. Reducing assembly time can have a significant impact on labour costs, particularly for manufacturers handling large volumes. Well-designed packaging solutions improve speed and consistency within warehouses, helping your teams work smarter.

 

Right Size Packaging Works Out Cheaper

Right Size technology, such as Ribble’s Right Size solution, allows manufacturers to create packaging that perfectly fits each product. By eliminating excess space, you can drastically reduce material usage, cut down on void fill and make shipments more compact.

With less air being transported, shipping becomes more efficient, reducing both costs and environmental impact. Right Size also helps protect products more effectively during transit, meaning fewer damages and returns to manage.

 

How Rationalisation Can Save Money

Rationalising your packaging range can unlock further savings. By reviewing your existing packaging inventory and reducing the number of different box sizes and styles, you can simplify procurement, storage and operations.

Bulk ordering fewer types of packaging often leads to better unit costs. It also simplifies training for assembly teams and improves warehouse space utilisation. For manufacturers dealing with multiple product lines, rationalisation can bring welcome clarity and efficiency without sacrificing the quality or protection of the products.

 

Packaging That Supports Your Business Growth

Choosing the right packaging partner can make a significant difference to your bottom line. At Ribble Packaging, we help businesses like you reduce packaging costs the smart way, without compromising on product protection, efficiency or sustainability.

Explore how our tailored solutions, including Right Size technology, can help your business. Get in touch today on 0161 284 9000.

Sustainable Packaging Solutions for Made-to-Order Businesses

Posted on by definitionconsulting

In industries that predominantly operate on a made-to-order basis, such as doors, panels or shutters, rising customer demand for environmental responsibility is pushing manufacturers to rethink their processes. Whether it’s reducing carbon emissions by changing material suppliers or upgrading packaging solutions, companies are increasingly seeking ways to align with sustainability while maintaining product protection, visual appeal and bottom-line profits.

Made-to-Order Packaging

Manufacturers in the doors, panels, and shutters industry cover a wide range of clients, from individual homeowners with smaller orders to large-scale construction projects. Regardless of the order size, packaging plays an important role in ensuring products arrive in perfect condition. Given the intricate finishes and personal details that often define these products, standard packaging solutions frequently fall short.

Traditional packaging practices, such as relying on oversized boxes and plastic void fillers, lead to unnecessary waste, higher costs and a greater risk of product damage. This is where Right Size packaging steps in to provide a more tailored, sustainable, and efficient solution.

The Benefits of Right Size Packaging

Right Size packaging is designed specifically for each product, minimising empty space in the box and reducing the need for filler materials. This approach not only lowers packaging costs but also significantly reduces the risk of damage during transportation, ensuring that products reach customers intact and undamaged.

Additionally, Right Size packaging streamlines production by enabling on-demand creation. This helps free up valuable warehouse space and increases the overall packaging process, contributing to a more efficient supply chain.

Case Study: Evergreen Shutters

We recently spoke with Evergreen Shutters, a leading manufacturer who faced packaging challenges due to the variety of custom-made shutters they produced. Standard packaging solutions led to excessive use of filler materials and frequent product damage. Their solution? Implementing Right Size packaging in partnership with Ribble Packaging. You can read the full case study to learn how Evergreen Shutters improved their packaging processes and saw long-term benefits from adopting Right Size packaging.

While transitioning to Right Size packaging is a commitment, the long-term benefits such as cost savings, reduced waste, and improved product protection are undeniable. Adopting made-to-order packaging is not just a practical step but a strategic decision that positions manufacturers for long-term success in a competitive and sustainability-focused market.

Take the Next Step with Ribble Packaging

If you’re ready to discover how custom packaging can transform your business, reach out to us at Ribble Packaging on 0161 284 9000 or through our website. Our team of experts can advise on the best options to meet your business needs, helping you enhance sustainability and reduce costs.

An Update on the EPR Regulations on Packaging and what that means for you

Posted on by definitionconsulting

Extended Producer Responsibility (EPR) has been introduced to reshape packaging waste management in the UK and Europe. If you want to understand more about how this will impact your packaging, then stick around.

As the environmental impact of packaging continues to draw public and governmental scrutiny, EPR regulations are increasingly mandating that producers take full responsibility for the lifecycle of their packaging. Effective from October 2025, these regulations are going to change how businesses approach packaging design, production and disposal.

What is EPR?

Extended Producer Responsibility (EPR) is a framework that assigns producers significant financial and physical responsibility for the treatment and disposal of post-consumer products. The primary goal of EPR is to incentivise producers to incorporate environmental considerations into the design of their products and packaging, ultimately reducing waste and promoting recycling.

Key Changes in the EPR Regulations

The upcoming EPR regulations in the UK bring several key changes that businesses need to be aware of:

  1. Producers will be required to cover the full net costs of managing packaging waste, including collection, sorting, recycling, and disposal. This includes payments to local authorities for handling household packaging waste​
  2. Companies must report on the packaging they place on the market. This data must be submitted bi-annually, covering the volume and type of packaging materials used, to ensure accurate calculation of waste management fees​
  3. Producers will need to obtain Packaging Waste Recycling Notes (PRNs) or Packaging Waste Export Recycling Notes (PERNs) as evidence that their packaging waste has been recycled. This system aims to ensure transparency and accountability in the recycling process​

    More information can be found here (GOV.UK)​​.

Impacts on Packaging Design and Materials

The new EPR regulations are set to also impact how businesses design and choose materials for their packaging. To comply with EPR standards, companies are encouraged to use sustainable and recyclable materials. This shift is driving innovation in packaging design, with many businesses exploring alternatives. In reviewing packaging, many companies have already seen a reduction in excess packaging through Right Size packaging.

While there may be initial costs associated with transitioning to sustainable packaging, the long-term benefits include reduced waste management expenses and improved resource efficiency. Additionally, compliance with EPR regulations can help companies avoid potential fines and penalties. Other benefits have shown companies that adopt sustainable packaging practices can improve their green credentials and appeal to environmentally conscious consumers, demonstrating a commitment to sustainability can differentiate a brand in a competitive market.

Practical Steps for EPR Compliance

Businesses across the UK should start by assessing their current packaging materials and practices to identify areas for improvement. Once identified, work closely with packaging suppliers to develop sustainable solutions that meet EPR standards. Suppliers like Ribble Packaging can offer expertise in optimising packaging and material selection.

Consult the Experts at Ribble Packaging

The EPR regulations mark a significant shift in how packaging waste is managed in the UK. While these regulations pose challenges for businesses in terms of increased costs and compliance requirements, they also offer opportunities for innovation and sustainability. By staying informed and proactively adapting to these changes, companies can not only comply with the regulations but also enhance their environmental impact.

At Ribble Packaging we specialise in providing EPR compliant packaging solutions tailored to your business needs through Right Size Packaging. Contact us today and see how we can help you understand the complexities of EPR regulations.

For more detailed information on the EPR regulations and their implementation, you can visit the official UK government pages (GOV.UK)​​.

Solving the Furniture Industry’s Damaged Goods Dilemma

Posted on by definitionconsulting

Furniture manufacturers face a common challenge; goods becoming damaged during transit.

The logistics of shipping bulky and irregularly shaped items often result in them arriving at their destination in less-than-ideal condition. However, a growing number of manufacturers are discovering a solution to this problem through investment in Right Size packaging technology, with companies like Panotec leading the charge.

The Damaged Goods Dilemma

For furniture manufacturers, damaged goods represent more than just a financial setback. They impact customer trust, harm brand reputation, and disrupt your supply chain. The nature of furniture, large, heavy, and often fragile makes it particularly susceptible to damage during transit. Traditional one-size-fits-all packaging methods often fall short of protecting these items, leading to an alarming rate of returns.

Right Size Packaging

Right Size packaging has changed the way furniture manufacturers approach packaging. Instead of using standardised boxes that leave unused space and excessive void filler, Right Size packaging involves customising packaging to fit each product’s exact dimensions. This tailored approach minimises wasted space, reduces the risk of product movement during transit, and enhances overall protection.

Who Are Panotec?

Panotec is a leader in automated packaging solutions, offering various systems that enable furniture manufacturers to optimise their packaging processes. By leveraging Panotec’s automated systems, manufacturers can produce custom-sized boxes on demand, ensuring that each item is packaged securely and efficiently. This not only reduces the likelihood of damage during transit but also streamlines operations and cuts down on material waste.

Benefits Beyond Damage Prevention

Investing in Right Size packaging with Panotec offers a host of benefits beyond mitigating damaged products. Manufacturers can enjoy cost savings through reduced shipping expenses and material usage. The efficiency gains achieved through automation enable companies to allocate resources more effectively, improving overall productivity and profitability. Additionally, embracing sustainable packaging practices aligns with consumer’s growing preference for eco-friendly brands.

Work with Ribble Packaging

Ribble Packaging has already been able to enhance the speed, accuracy, and cost-effectiveness of furniture packaging processes for the likes of Wren Kitchens, One Call Furniture, Magnet and BA Components to name but a few by adopting Right Size packaging with Panotec.

As the furniture industry continues to evolve, packaging will play an increasingly important role in shaping the customer experience. By prioritising investment in Right Size packaging technology, manufacturers can stay ahead of the curve and position themselves for long-term success.

If you would like to discuss the possibilities of Panotec, get in contact.

Why Packaging Waste Matters: New Extended Producer Responsibility (EPR) Updates

Posted on by definitionconsulting

The way we package our goods can significantly contribute to a better planet, so it’s no surprise the spotlight is now on sustainability in packaging practices, with updated regulations on packaging waste set to come in October 2025.
These regulations come in the form of Extended Producer Responsibility (EPR), a regulatory framework aimed at changing how we approach packaging waste. Whether you’re sourcing materials domestically or relying on imports, this impending scheme is set to reshape your packaging operations.
This blog serves as an informative follow-up to our previous discussions on the topic, providing the latest updates on EPR.

Understanding EPR

At its core, EPR shifts the responsibility for packaging waste management onto producers, requiring them to bear the full cost of collection, sorting, treatment, and recycling. Recent updates to EPR regulations have brought about significant changes, including the introduction of modulated fees. The payment year has also been deferred from October 2024 to October 2025, however, businesses are still required to declare their packaging waste for 2023.
This initiative is driven by the objective of incentivising producers to limit packaging waste and enhance recyclability. This shift inevitably carries financial implications, as costs are predicted to increase. Therefore, it’s important to understand how EPR will influence your packaging operations and how you can proactively mitigate associated expenses.

Aligning Packaging Practices with EPR

EPR encourages producers to rethink packaging choices and design, urging businesses to embrace recyclable materials and eco-design principles while reducing waste. As companies gear up to comply with EPR regulations, it’s clear that innovative solutions will be essential in meeting these new standards effectively.

How can Right Size Packaging Help?

Right Size solutions combine Ribble’s industry-leading Fanfold material and state-of-the-art technology to create the perfect size box for all products. This ensures every item of packaging fits the product exactly, negating the need for void fillers and excess packaging.
We have a simple 4-step process for our Right Size solutions:
1. Enter box style and dimensions.
2. Select how many are required.
3. The box is produced within seconds.
4. Products are packaged in the perfect-sized box.

As well as saving on EPR tax, businesses will save on fuel and transport costs, regain warehouse space and save on labour costs, all resulting in up to 30% savings on packaging costs.
If you would like to discuss EPR in more detail with some of the packaging experts at Ribble Packaging, you can contact us at info@ribble-pack.co.uk or visit our contact page.

Print & POS Companies Deserve Better Packaging

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Many print & POS companies are finding their hard work undone due to improper packaging.

Print and POS are often known for their creativity, but delivering exceptional work to clients extends beyond the ink on the page or setting up a sales display – it’s about ensuring that it arrives in pristine condition. The journey from print to delivery is often overlooked, yet it presents a significant opportunity to increase profits simply by embracing efficient packaging practices.

Why Efficient Packaging is Important

Efficient packaging serves as more than just a protective means during delivery, it should be considered an investment that saves time, money, and resources. By streamlining packaging processes, print and POS companies not only reduce the risk of damaged stock, but also reduce unnecessary expenses associated with overstocking and wasteful packaging materials. For instance, efficient packaging can lead to faster order fulfilment, reducing labour costs and improving customer satisfaction.

Additionally, companies embracing sustainable packaging practices not only return better cost savings but also contribute to a healthier planet, aligning with the growing pressures on corporate social responsibility. According to a recent study, just a 1% increase in CSR investments leads to a 0.3% increase in sales growth.

Right Size Packaging Solution

Right Size is the development of on demand packaging production. This technology enables companies to produce packaging precisely tailored to the dimensions of each product, eliminating the need for excessive filler or wasted space.

Working with Fanfold corrugated material offers the perfect solution to addressing the challenges of varied job sizes and delicate displays. With Right Size packaging, print & POS companies can begin to modernise their packaging operation and reduce expenditure.

Whether handling small scale print orders or large format POS displays, these solutions can adjust to accommodate various requirements allowing companies to innovate and expand their offerings. With the flexibility of Right Size solutions, you remain agile and responsive.

Ribble Packaging

By embracing Right Size packaging solutions print and POS companies can unlock substantial cost savings while delivering undamaged products to your clients.

Learn more about Ribble’s Right Size Packaging Solutions and how they can benefit your Print or POS business today. If you want to speak about your packaging needs in greater detail, call us on 0161 284 9000.

Bulk Buying Doesn’t Always Mean Savings

Posted on by definitionconsulting

The way products are packaged can significantly impact a company’s bottom line, and for years the go-to strategy has been bulk buying both packaging materials and void filler, but what many fail to realise are the hidden costs associated with this traditional approach.

Rethinking Bulk Buying

Bulk buying packaging materials has long been the default option for many companies due to the attractive discounts offered on larger quantities. Yet, this seemingly cost-effective strategy may be putting a strain on your warehouse space. Worse yet, if you cater to many different sized products, your packaging can sit for long periods of time.

However, there is a more efficient and cost-effective way to approach your packaging…

Getting it Right First Time

Investing in Right Size packaging solutions can significantly reduce packaging costs by up to 40%. It is already being utilised by various industries, from furniture to manufacturing. This approach is centred on efficiency and cost-effectiveness, as companies use rolls of fanfold cardboard that adapt to different product shapes and sizes seamlessly.

This works by scanning and entering the box style and dimensions, selecting the quantity required then your box is produced within seconds. With this precise customisation, it allows for the perfect sized box every time, eliminating any need for void filler, meaning less clutter and the opportunity to optimise your warehouse space.

Real Packaging Cost Savings

One of our clients, BG Sports, struggled with their packaging as they shipped sports memorabilia in all different shapes and sizes. Bulk buying packaging was inefficient and ordering smaller quantities was too expensive. With the business growing, space started to become an issue, and that’s why they invested in Right Size solutions. They achieved a significant reduction in packaging material usage and storage costs, reducing their packaging bill from £400k a year down to £200k, thanks to the adoption of Ribble’s Right Size. Read more about their story here.

The benefits of Right Size packaging extend beyond this case study. It also reduces material wastage, lowers shipping expenses, decreases product damage and returns, maximises shipping capacity, and helps businesses adapt to price increases in the supply chain. Companies that adopt this approach not only contribute to environmental sustainability but also witness a positive impact on their bottom line, making it a win-win solution.

Choosing Ribble Packaging

As businesses reassess their packaging strategies, we encourage you to explore the many costs saving benefits with Right Size solutions. At Ribble Packaging, we specialise in providing tailored solutions that align with your business needs. Contact us today on 0161 284 9000.

How Right Size Technology can save you thousands on fuel and energy costs

Posted on by definitionconsulting

In 2020 1.27 billion tonnes of goods were carried by trucks and HGVs across the UK, covering 16.2 billion road miles.

Due recent socioeconomic and political factors the cost to fuel these HGVs has risen by £173 per week. Diesel has hit a record high of £1.70 per litre, while petrol now costs an average of £1.61 per litre.

With fuel and energy costs soaring; Inflation is at its highest level for over 30 years, with much of these rises passed onto the consumer as firms simply cannot absorb such significant increases (Elizabeth de Jong, Logistics UK).

 

What’s Happening Now?

Fuel accounts for a third of an HGV’s annual operating cost.”  So ‘The Road Haulage Association’ wants the Government to freeze fuel duty for two years. It also wants an “essential user” rebate for lorry and coach firms of 15p per litre introduced.

Rising fuel prices are putting further pressure on retail supply chains. This adds to cost pressures from labour shortages, commodity price increases and rising energy prices in consequence, until some pressures ease, it’s likely prices will continue to rise.

Meanwhile, analysis shows the annual average cost of running a typical family car, including fuel, has shot up by nearly £300. Many consumers are having to choose between purchasing food, heating their homes or putting petrol in their cars.

 

How Ribble Right Size Can Help?

Many people overlook the importance of packaging when it comes to shipping goods, but an efficient and effective packaging supply is essential to keeping the product safe and most importantly keeping customers happy.

Ribble Right Size solutions improve vehicle utilisation by 25%. This means companies who have implemented Right Size can fit 25% more product in each vehicle drastically decreasing fuel consumption.

By Right Sizing your packaging supply you will gain the ability to create the perfect size box for all your products on-site, on-demand, eliminating any wasted space in your packages and therefore any wasted space in your transport vehicle.

With Right Size there is no need for additional protective packaging materials such as bubble wrap or Styrofoam peanuts as your boxes will now fit your products perfectly, increasing product protection, decreasing the weight of your packages, and making your packaging process fully sustainable.

There are also many other benefits of using our Right Size solutions. These include up to a 30% reduction in packaging costs, savings on labour costs through increased automation, increased warehouse space and more.

Every cubic inch of your packaging that doesn’t contain your product is costing you money. By introducing Right Size Technology, you can get more boxes in each vehicle, meaning fewer journeys and less money spent on fuel and diesel.

 

How sustainable is your Christmas packaging?

Posted on by definitionconsulting

It’s that time of year again. The time that we do everything in excess, from food, to spending.

But does that mean you have to have an unsustainable Christmas?

As we all know, Christmas can be a time for spending time with loved ones and exchanging gifts, but with it is estimated that around 1 in 4 households will be generating up to 5 bags of rubbish this Christmas!

Much of children’s toys are packaged in plastic or oversized packaging which is bulky and often unnecessary for the size of the present inside. On top of that, there is wrapping paper which, often, you are unable to recycle, which then doubles the amount of waste.

Let’s not forget about the Christmas dinner. Single use plastics have come to the forefront of the sustainable packaging discussion, many of which occur as a result of food packaging.

How can you make your Christmas more sustainable?

It is everybody’s responsibility, to make small changes this Christmas in an effort to reduce the amount of waste created within the household. So, we have put together a few pointers that may help you make some more sustainable choices.

Recyclable wrapping paper

If you’re unsure about what wrapping paper can be recycled and what can’t, it’s important to check with your local recycling centre. Recycle Now have some great pointers on what you can do to ensure that your paper does actually get recycled if accepted at your local centre, including:

  • Making sure all sticky tape, bows and ribbons are removed before recycling
  • Only recycling simple wrapping paper that doesn’t have any glitter or foil as these cannot be recycled.

Present sacks

Another way to reduce the waste this Christmas is to purchase some present sacks & stockings. These can be brought back out every Christmas and eliminate the need to wrap your gifts or find recyclable wrapping paper.

Food & drinks using sustainable packaging

Many supermarkets are introducing refillable packaging services within their stores and this is likely to continue. Why not check out your local supermarket to see if there are any ingredients in your Christmas dinner that could be switched out for a more sustainably packaged option?

Ribble Right Size

At Ribble our aim is to introduce Right Size packaging to more and more manufacturers so that we can help reduce the overall waste when it comes to cardboard packaging.

 

Get in touch today to find out more about the benefits of Right Size.

How to take back control of your packaging supply in 2021

Posted on by definitionconsulting

Deemed the new ‘beige gold’, cardboard supply is still very much in high demand as a result of the ongoing coronavirus pandemic and the dramatic increase in online shopping has led to this over the past 12 months.

According to The IMRG Capgemini Online Retail Index, the UK’s eCommerce sector achieved the highest online sales growth in 13 years. Total online retail sales growth was up 36% in 2020, so it’s not surprising the devastating effects this has had on businesses nationwide.

Struggling to cope with cardboard material supply, many online retailers have experienced a delay in their deliveries, which in turn has been impactful on their customer satisfaction. Even the big retailers, Asda, Lidl and the Co-op started to feel the pinch early on last year, as many consumers were asking why their egg packaging was replaced with plastic packaging. This was an early warning of what was to come for the world of packaging…

Before the pandemic, businesses were relatively responsible when it came to recycling. Packaging would be quickly returned into the recycling system, but now the industry tackles the problem of relying on individuals to recycle properly.

“What we’ve found is people tend to store product boxes in their garages or simply in their homes without realising the detrimental effects this is having on cardboard supply,” says Stephen Rector, Managing Director at Ribble Packaging.

Less recyclable cardboard is being returned into the system and paper manufacturers are struggling to create the supply to meet demand. Paper has become scarce, and some corrugated manufacturers are having to ration their supply and let customers down.

So how can you future-proof your packaging supply chain in a volatile market?

By implementing a Right Size packaging solution.

Fit-to-product boxes can help by considerably cutting the amount of cardboard you use. By only using the right size box, it means you only have to purchase one type of packaging material such as Fanfold, removing the need to order multiple styles and sizes.

This flexible on-demand right size packaging solution is guaranteed to save you up to 25% in packaging costs and is a much more sustainable solution, as it removes the need to purchase additional void fillers; a win, win.

To find out more about Ribble Right Size, please click here or get in touch and we’d be happy to discuss your options.

 

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